Automation Manages Robust HACCP (and HARPC!) Programs

Make Sure HACCP/HARPC Programs are Being Followed to a “T.” One of the biggest challenges to managing a successful HACCP/HARPC plan is to ensure that you are “saying what you do, doing what you say, making sure it works, and making sure it’s documented.” Are all facilities and suppliers following your most current plan(s)? Using the most up-to-date forms? Ensuring proper records for pre-shipment reviews? HACCP/HARPC automation addresses these challenges in the following ways.

• Some automated systems will provide pre-built form configuration templates that allow you to easily set up your HACCP/HARPC program requirements and ensure that only the most up-to-date plans and forms are used.
• If you have task scheduling features, all of your CCPs, PRPs, and other tasks can be defined and scheduled for due dates/times/frequency. Non-completion notifications, which can typically be sent via text and email to identified stakeholders, can ensure that tasks get completed on time and help avoid rework and shipment delays.
• Workflow verification can be auto-­generated, including pre-shipment review authorizations and positive releases, with e-signatures. Depending on the size and complexity of operation, you may choose to integrate your HACCP/HARPC solution with Enterprise Resource Planning or Materials Resource Planning systems—signaling product acceptance and release.
• Most HACCP/HARPC systems have a variety of real-time dashboards that can display trends for compliance status of sanitation and environmental controls, pest control, preventive maintenance, test/task data results, CAPAs, and other program components. If the solution you implement has a mobile application, you can monitor the program from anywhere there is an Internet connection via a laptop, tablet, or smartphone.
• Automation allows new and updated requirements to be “cascaded” throughout your food supply chain so compliance is immediately enforced by ensuring that only current plans and forms are used by suppliers, in your plants, and for documents sent to customers prior to shipment.

Respond to Audits and Inquiries in a Matter of Minutes vs. Hours or Days. Responding to HACCP/HARPC program questions—during a USDA inspection, FDA inquiry, or perhaps a customer audit—is time-consuming and disruptive to operations. Additionally, if records can’t be located or verified, regulatory audit expansion is very likely to occur and business relationships can be damaged. HACCP/HARPC automation can help you be ready 24/7/365 for such audits and inquiries by allowing you to perform the following functions.

• Search a central repository of the relevant program data—in most solutions both current and historical—for fast, accurate response.
• Auto-organize all relevant documents for each type of audit by product, facility, incident, or any other parameter required by HACCP/HARPC plan(s).
• Bring a new level of efficacy to FDA and USDA program compliance with unalterable time/date stamps offered by some HACCP/HARPC automation solutions.

Building a Business Case for Buy-In

This all sounds pretty good, right? But given low food industry profit margins, it’s often necessary to be able to build an ROI-based business case for technology investments. If we think about the other types of automation solutions that many food companies have in place—such as human resources or financial applications—they were approved because they save time, save money, and create efficiencies to provide ROI. This same holds true for FSQA technology, including HACCP/HARPC systems. These solutions also save time and money and create operational efficiencies that streamline and improve program management.

Examples of ways in which HACCP/HARPC automation can create ROI include the following.

• Reduction of manual labor: automated task monitoring and population of direct observation forms via mobile devices, or direct data entry into the system, not only increases accuracy—these capabilities also result in time/labor savings due to a reduction in manual processes and related errors.
• Faster product throughput: automatic COA generation, when no non-conformances are detected, allows product to move faster to the next point in your value chain—meaning that shipment to customers can be expedited.
• Reduction in the cost of non-conformance: real-time data analysis and timely CAPAs help manage product risks, minimizes product rework, and expedites product release times.

In Summary

HACCP plan management does not have to be a time-consuming, error-prone practice that lends itself to food safety professionals spending more time entering data versus analyzing it to find areas for FSQA improvement. By leveraging HACCP/HARPC automation innovations, food and beverage companies can manage robust and complex plans, maximize compliance, minimize non-conformances, promote audit readiness, and create ROI.